no wonder it didn't start

A

AndyP

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Noticed some flickering of dash lights one day when turning on the engine. Didn't think of it much - it was really cold that day. A few days later - nothing when turning the key. Wiggled the steering wheel and lights flickered. Removed the steering column cover and found the end of the ignition switch was unplugged. Now how the heck can this happen? Pushed it back in, it's still loose, but car runs. Actually seems to start much easier. Probably won't be able to avoid dealing with the infamous "grub screw" and pulling the back of the starter switch for better access. Any thoughts on permanent attachment (rather than replacement)?
 

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Had a similar thing happen to an E30 ignition switch and was able to use a couple zip-ties to hold it in place (attached around the entire housing like a craddle. Not sure that will work on yours though.
 
A close

inspection reveals that the end is simply staked. Find a suitable wedge ( wooden shim cut to size) to hold it back in place and restake it with a punch in at least two of the three places. (I've done it twice to the original) I have thought about a well placed drop of epoxy too.

Common occurence since the switch twists naturally by the key action in the start position.
 
Oh no

Be careful if you try and re-stake....the plastic, phenolic? Shatters like china. High end two part adhesive? Might work. That piece is what? $200 + Falls on my list of another E9 cheesy bit. Sort of like the visors or the clam shell tool box...under-engineered for sure and prone to failure. I have one kicking around the shop, broken same as your picture. Let me see if I can fix it....EZ to draw that piece out....jewellers screw driver to the grub screw. I ran for a while when my intermediate section wore out....screw driver to start the car with the switch dangling.
 
Thanks!

Thanks for the thoughts guys. I like the zip tie idea, gotta see if there is room in there. Epoxy is probably the best bet to keep it in place. I am just glad to hear that this is nothing unusual, and it can be rigged rather than replaced. I'll play around with it and report back. Cheers!
 
Andy, rather than an epoxy that dries super-hard, I'd prefer something that dried "almost hard" so you could, someday, if the notion struck you, take the cylinder out again.

So what's that potion going to be...? Maybe some carpenter's yellow glue... maybe something from my collection of caulkings... but it's your car, use whatcha got.
 
got a new one

Wasn't able to plug it back in, so I got a new one. Harold in Mountain View put it back in for me. $290 for the part. Car runs great.
 
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